Electrostatic Spray Drying for Oil Powders

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Solution Overview

Problem

Conventional spray drying systems for producing oil powders operate at high temperatures, which can degrade oils and limit their loading capacity and encapsulation efficiency, making them less shelf-stable.

Innovation Solution

Electrostatic spray drying is used at inlet temperatures of 150° C. or below and exhaust temperatures of 100° C. or below, applying a voltage to the spray droplets to enhance encapsulation efficiency and loading capacity while maintaining lower temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional spray drying is used to produce oil powders, then the drying efficiency is high, but the oil degrades due to high temperatures and the encapsulation efficiency is limited

Engineering Contradiction:

Improvedrying efficiencyVSAvoidoil degradation

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the temperature parameters from conventional high-temperature spray drying (inlet temperature typically 150-200°C) to low-temperature electrostatic spray drying (inlet temperature 50-150°C, preferably 80-120°C). This parameter change reduces thermal damage to oil while maintaining drying efficiency through the electrostatic field's enhanced evaporation rate.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the conventional thermal-driven spray drying system with an electrostatic field-based system. By applying high voltage (5-50 kV) to the spray nozzle, the system uses electrostatic forces to accelerate droplet evaporation and improve encapsulation, substituting thermal energy with electrical energy as the primary driving force.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If conventional spray drying is used, then the process is simple, but the loading capacity and encapsulation efficiency are limited

Engineering Contradiction:

Improveprocess simplicityVSAvoidloading capacity

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent introduces an electrostatic field generation system (high voltage power supply and charged spray nozzle) to replace conventional spray drying. This substitution enables significantly higher oil loading capacity (up to 80-90% oil content in the emulsion) and improved encapsulation efficiency (90-99%) while maintaining operational simplicity through automated voltage control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method results in oil powders with improved shelf stability, higher loading capacity, and enhanced encapsulation efficiency compared to traditional spray drying, with lower surface free fat and higher encapsulation efficiency, maintaining quality and stability.

Implementation Method 1

electrostatic spray drying is used at inlet temperatures of 150° C. or below and exhaust temperatures of 100° C. or below, applying a voltage to the spray droplets

Methodology Applied

Scientific EffectElectrostatic effect: Electrostatics

Data Source

PatentUS20240359151A1Electrostatic spray dried oil powders and production method thereof

Publication Date: 2024.10.31 SPRAYING SYSTEMS CO

AI summary

Provided is a method of providing an oil emulsion powder comprising electrostatic spray drying an emulsion comprising at least one oil, an encapsulating agent, and optionally an emulsifier at an inlet temperature of 150° C. or below and an exhaust temperature of 100° C. or below.